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Additive Manufacturing and Innovative Welding Technologies for Light Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 May 2021) | Viewed by 14861

Special Issue Editors


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Guest Editor
Faculty of Mechanical Engineering, Military University and Technology, 2 Kaliskiego Street, 00-908 Warsaw, Poland
Interests: fatigue strength; friction stir welding; additive manufacturing technologies
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of Machine Design, Rzeszow University of Technology, 35-959 Rzeszow, Poland
Interests: additive manufacturing; 3D printing; CAD design; mechanical engineering; smart production; VR; IoT
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of Manufacturing Engineering and Production Automation, Faculty of Mechanical Engineering, Opole University of Technology, 5 Mikolajczyka Street, 45-271 Opole, Poland
Interests: surface metrology; optimization of difficult-to-cut materials; sensor technology; metrology; measurement uncertainty; environmental measurement; optimization of geometrical and physical parameters of surface integrity
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Advanced welding and additive manufacturing technologies are characterized by tremendous industrial and academic interest. One of the most important issues connected with the usage of the aforementioned technologies is their capacity of production of lightweight components with high geometrical complexity and very good mechanical properties in comparison with conventional processes. Technologies, which are the main topic of the issue, provide significantly higher design freedom, especially for single or low series production. All these advantages go hand in hand with optimal design theory, very often based on topological optimization. However, the mechanical performance of the elements obtained using innovative welding technologies or produced using additive manufacturing technologies has not been clarified yet.

The main scope of this Special Issue is to provide specialistic, scientific knowledge from all fields involving mainly mechanical properties and structural analysis. The issue is dedicated to a wide range of applications, including mechanical engineering, biomedical engineering, civil engineering, material science, manufacturing, nanotechnology, tribology, and others.

Prof. Lucjan Śnieżek
Prof. Grzegorz Budzik
Prof. Grzegorz Królczyk
Guest Editor

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Keywords

  • Addictive manufacturing
  • Welding technologies
  • Light alloys
  • High geometrical complexity
  • Topological optimization

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Published Papers (5 papers)

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Research

20 pages, 10371 KiB  
Article
Corrosion Resistance Measurement of 316L Stainless Steel Manufactured by Selective Laser Melting
by Rigoberto Guzmán-Nogales, Francisco Estupiñán-López, Citlalli Gaona-Tiburcio, Omar E. Lopez-Botello, Juan G. Ramírez-Rodríguez and Patricia C. Zambrano-Robledo
Materials 2021, 14(16), 4509; https://doi.org/10.3390/ma14164509 - 11 Aug 2021
Cited by 8 | Viewed by 2296
Abstract
Selective laser melting (SLM) technology is ushering in a new era of advanced industrial production of metal components. It is of great importance to understand the relationship between the surface features and electrochemical properties of manufactured parts. This work studied the influence of [...] Read more.
Selective laser melting (SLM) technology is ushering in a new era of advanced industrial production of metal components. It is of great importance to understand the relationship between the surface features and electrochemical properties of manufactured parts. This work studied the influence of surface orientation on the corrosion resistance of 316L stainless-steel (SS) components manufactured with SLM. The corrosion resistance of the samples was measured using linear polarization resistance (LPR) and electromechanical noise (EN) techniques under three different environments, H2O, 3.5 wt.% NaCl, and 20% H2SO4, analyzing the horizontal (XY) and vertical (XZ) planes. The microstructure and morphology of the samples were obtained by optical (OM) and scanning electron microscopy (SEM). The obtained microstructure showed the grains growing up from the fusion line to the melt pool center and, via SEM-EDS, the presence of irregular and spherical pores was observed. The highest corrosion rate was identified in the H2SO4 solution in the XZ plane with 2.4 × 10−2 mm/year and the XY plane with 1.31 × 10−3 mm/year. The EN technique along with the skewness factor were used to determine the type of corrosion that the material developed. Localized corrosion was observed in the NaCl electrolyte, for the XY and XZ planes (−1.65 and −0.012 skewness factors, respectively), attacking mainly the subgrains of the microstructure and, in some cases, the pores, caused by Cl ions. H2O and H2SO4 solutions presented a uniform corrosion mechanism for the two observed orientations. The morphology identified by SEM was correlated with the results obtained from the electrochemical techniques. Full article
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16 pages, 5717 KiB  
Article
Mechanical Properties Analysis of the AA2519-AA1050-Ti6Al4V Explosive Welded Laminate
by Ireneusz Szachogluchowicz, Lucjan Sniezek, Tomasz Slezak, Janusz Kluczyński, Krzysztof Grzelak, Janusz Torzewski and Teresa Fras
Materials 2020, 13(19), 4348; https://doi.org/10.3390/ma13194348 - 30 Sep 2020
Cited by 7 | Viewed by 2174
Abstract
Explosively welded layered materials made of (a) an AA2519 aluminum alloy (AlCuMgMn + ZrSc), (b) titanium alloy Ti6Al4V and (c) an intermediate layer composed of a thin aluminum alloyed AA1050 layer are considered herein. This study presents test results connected to measurement science [...] Read more.
Explosively welded layered materials made of (a) an AA2519 aluminum alloy (AlCuMgMn + ZrSc), (b) titanium alloy Ti6Al4V and (c) an intermediate layer composed of a thin aluminum alloyed AA1050 layer are considered herein. This study presents test results connected to measurement science including microstructural observations of the material combined with the explosive method, and a basic analysis of the strength properties based on microhardness and tensile tests. Owing to the joint’s special manufacturing conditions, the laminate was subjected to deformation measurements with the digital image correlation (DIC) method. The research was supplemented by the residual stress measurements with the sin2ψ X-ray method based on the diffraction–reflection analysis that was verified by the bore trepanation method. Full article
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16 pages, 22457 KiB  
Article
Comparison of Different Heat Treatment Processes of Selective Laser Melted 316L Steel Based on Analysis of Mechanical Properties
by Janusz Kluczyński, Lucjan Śnieżek, Krzysztof Grzelak, Artur Oziębło, Krzysztof Perkowski, Janusz Torzewski, Ireneusz Szachogłuchowicz, Krzysztof Gocman, Marcin Wachowski and Bogusz Kania
Materials 2020, 13(17), 3805; https://doi.org/10.3390/ma13173805 - 28 Aug 2020
Cited by 19 | Viewed by 2783
Abstract
In this study, we analyzed the mechanical properties of selectively laser melted (SLM) steel obtained via different modifications during and after the manufacturing process. The aim was to determine the effects of precipitation heat treatment on the mechanical properties of elements additively manufactured [...] Read more.
In this study, we analyzed the mechanical properties of selectively laser melted (SLM) steel obtained via different modifications during and after the manufacturing process. The aim was to determine the effects of precipitation heat treatment on the mechanical properties of elements additively manufactured using three different process parameters. Some samples were additionally obtained using hot isostatic pressing (HIP), while some were treated using two different types of heat treatment and a combination of those two processes. From each manufactured sample, a part of the material was taken for structural analysis including residual stress analysis and microstructural investigations. In the second part of the research, the mechanical properties were studied to define the scleronomic hardness of the samples. Finally, tensile tests were conducted using a digital image correlation (DIC) test and fracture analysis. The treated samples were found to be significantly elongated, thus indicating the advantages of using precipitation heat treatment. Additionally, precipitation heat treatment was found to increase the porosity of samples, which was the opposite compared to HIP-treated samples. Full article
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14 pages, 15212 KiB  
Article
Crack Growth Behavior of Additively Manufactured 316L Steel—Influence of Build Orientation and Heat Treatment
by Janusz Kluczyński, Lucjan Śnieżek, Krzysztof Grzelak, Janusz Torzewski, Ireneusz Szachogłuchowicz, Marcin Wachowski and Jakub Łuszczek
Materials 2020, 13(15), 3259; https://doi.org/10.3390/ma13153259 - 22 Jul 2020
Cited by 23 | Viewed by 3191
Abstract
The effects of build orientation and heat treatment on the crack growth behavior of 316L stainless steel (SS) fabricated via a selective laser melting additive manufacturing process were investigated. Available research results on additively manufactured metallic parts still require a substantial expansion. The [...] Read more.
The effects of build orientation and heat treatment on the crack growth behavior of 316L stainless steel (SS) fabricated via a selective laser melting additive manufacturing process were investigated. Available research results on additively manufactured metallic parts still require a substantial expansion. The most important issue connected with the metal properties after additive manufacturing are the high anisotropy properties, especially from the fatigue point of view. The study examined the crack growth behavior of additively manufactured 316L in comparison to a conventionally made reference material. Both groups of samples were obtained using precipitation heat treatment. Different build orientations in the additively manufactured samples and rolling direction in the reference samples were taken into account as well. Precipitation heat treatment of additively manufactured parts allowed one to achieve microstructure and tensile properties to similar to those of conventionally made pieces. The heat treatment positively affected the fatigue properties. Additionally, precipitation heat treatment of additively manufactured elements significantly affected the reduction of fatigue cracking velocity and changed the fatigue cracking mechanism. Full article
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14 pages, 6985 KiB  
Article
Microstructure and Low Cycle Fatigue Properties of AA5083 H111 Friction Stir Welded Joint
by Janusz Torzewski, Krzysztof Grzelak, Marcin Wachowski and Robert Kosturek
Materials 2020, 13(10), 2381; https://doi.org/10.3390/ma13102381 - 21 May 2020
Cited by 30 | Viewed by 3381
Abstract
The present paper aims to analyze the microstructure, microhardness, tensile properties, and low cycle fatigue (LCF) behavior of friction stir welded (FSW) butt joints. The material used in this study was the 5 mm thick 5083 H111 aluminum alloy sheet. Butt joints of [...] Read more.
The present paper aims to analyze the microstructure, microhardness, tensile properties, and low cycle fatigue (LCF) behavior of friction stir welded (FSW) butt joints. The material used in this study was the 5 mm thick 5083 H111 aluminum alloy sheet. Butt joints of AA 5083 H111 were manufactured at different operating parameters of the FSW process. The effect of the welding parameters on microstructure, microhardness, and tensile properties was investigated. Based on microstructure analysis and strength tests, the most favorable parameters of the FSW process were settled on the point of view of weld quality. Then, LCF tests of base material and friction stir welded specimens made of 5083 H111 were carried out for the examined welded samples under selected friction stir welding parameters. The process of low-cycle fatigue of 5083 H111 aluminum alloy was characterized by cyclic hardening for both: base material and FSW joint. It was revealed by a decrease in the width of the hysteresis loop with the simultaneous significant increase in the values of the range of stress. It was determined that fatigue cracks are initiated by cyclic slip deformation due to local stress concentration from the surface in the corner of the samples for the base material and the heat-affected zone for FSW joints. For all tested strain amplitudes, the fatigue crack propagation region is characterized by the presence of fatigue striation with secondary cracks. Full article
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